Process control and data collection system

Abstract

A process control and data collection system which analyzes the data collected to provide information regarding the quality of the raw material supplied by specific vendors, the quality of production for a particular job, the efficiency and quality of the employee's work and the effective yield from raw material to final product on a batch basis. Each of a plurality of remote stations include input devices for providing a measurement of the raw material being processed whether it be weight, count or quality as well as identifying data which may include workstation identification, employee identification, work product identification and processing time. This allows correlation and tracking of the material from the beginning to the end of the process through various steps and comingling of raw materials.

What is claimed is: 
     
       1. A processing line data acquisition system for a process line having a sorting and first and second raw material processing steps comprising: sorting means for sorting an identified batch of raw material by a preselected criteria into a plurality of grades;   first measuring means for measuring total quantity of each grade of raw material sorted by said sorting means for a batch;   second measuring means for measuring a quantity of raw material after a first raw material processing step for portions of identified batches;   third measuring means for measuring a quantity of processed material after a second processing step for portions of said identified batches; and   central computer means connected to said sorting means and each measuring means for collecting and correlating the quantities measured on an identified batch basis.   
     
     
       2. A system according to claim 1 including: first input means at said first measuring means and connected to aid central computer means for inputting batch identifying data to said central computer means;   second input means at said second measuring means and connected to said central computer means for inputting batch identifying data to said central computer means; and   third input means at said third measuring means and connected to said central computer means for inputting batch identifying data to said central computer means.   
     
     
       3. A system according to claim 2, wherein said first input means includes means for inputting source of said batch, estimated grade, and batch identification. 
     
     
       4. A system according to claim 3, wherein said first input means further includes means for inputting preprocessing sub-batch identification by grade, said second input means includes means for inputting said preprocessing sub-batch identification and Post-processing sub-batch identification, and said third input means includes means for inputting said post-processing sub-batch identification. 
     
     
       5. A system according to claim 4, wherein said first input means further includes means for inputting workstation identification and operator identification; and said second and third inputs means further include means for inputting workstation identification, operator identification and duration of processing step. 
     
     
       6. A system according to claim 1, wherein said first, second and third measuring means measures the weight. 
     
     
       7. A system according to claim 1, wherein said sorting means sorts into grades by size and said first measuring means measures weight of said sorted raw material. 
     
     
       8. A system according to claim 1, wherein said second measuring means includes sensing means for sensing weight and local computer means connected to said sensing means for calculating a weight from said sensed weight and calculating a total weight for a series of sensed weights. 
     
     
       9. A system according to claim 8, including input means connected to said local computer means for inputting batch identify data and employee identity data for each sensed weight. 
     
     
       10. A system according to claim 1, wherein said third measuring means includes sensing means for sensing weight, input means for inputting grades and target weight, local computer means connected to said sensing means and input means for calculating the difference between the sensed weight and the target weight and calculating from the grade the number of processed items to be added to reach said targeted weight. 
     
     
       11. A method of monitoring processing of a batch of raw material comprising the steps of: sorting a batch of raw material by a preselected criteria into a plurality of grades;   measuring total quantity of each grade of raw material for said batch;   processing said sorted batch of raw material which results in a loss of quantity;   measuring the resulting quantity of said batch after said first processing step;   packing said processed raw material with a given quantity per package; and   counting total number of resulting packages for said batch.   
     
     
       12. A system according to claim 11, including filling means between said sorting means and said sensing means for filling containers on said sensing means to a desired weight under the control of said local computer means. 
     
     
       13. A system according to claim 12, wherein said local computer means includes means to accumulate a plurality of weights for a plurality of tar switch means activation to produce a total batch weight. 
     
     
       14. A method of monitoring processing of a batch of raw material comprising the steps of: sorting a batch of raw material by a preselected criteria into a plurality of grades;   measuring the quantity of each grade of raw material for said batch;   processing said sorted batch of raw material which results in a loss of quantity;   measuring the resulting quantity of said batch after said first processing step;   packing said processed raw material with a given quantity per package; and   counting the number of resulting packages for said batch.   
     
     
       15. A method according to claim 14, wherein said sorting step includes sorting by size and said first mentioned measuring step includes weighing. 
     
     
       16. A method according to claim 14, wherein said processing step includes removing the desired material from its casing and wherein said second mentioned measuring step includes weighing said resulting desired material. 
     
     
       17. A method according to claim 14, wherein said packing includes packaging a given weight of processed raw material. 
     
     
       18. A method according to claim 14, wherein said first mentioned measuring step includes dividing each of said grades into preprocessing sub-batches of a predetermined quantity. 
     
     
       19. A method according to claim 18, wherein said processing step includes subdividing a sub-batch into a plurality of micro-batches to be processed and said second mentioned measuring step includes measuring individually processed micro-batches and combining them to meet a target quantity. 
     
     
       20. A method according to claim 14, wherein said packaging step includes weighing the contents of a package during packaging, and displaying the number of items of processed raw material needed to meet a target weight. 
     
     
       21. A system for sorting a batch of raw material comprising: sorting means for storing a batch of raw material by preselected criteria into a plurality of grades;   a plurality of dispensing means each for receiving from said sorting means and dispensing a grade of sorted raw material;   a plurality of control means each connected to and controlling a respective dispensing means to dispense preselected quantities of sorted raw material to form sub-batches of a grade of a batch; and   interface means connected to said plurality of control means for coordinating the operation of and collecting quantity data from said plurality of control means and for determining a total quantity per grade for said batch.   
     
     
       22. A system according to claim 21, wherein each of said control means includes scale means for sensing weight and scale control means responsive to said scale means for controlling said dispensing means to dispense a preselected weight of said raw material to form a sub-batch. 
     
     
       23. A system according to claim 22, wherein each of said control means further includes tar means connected to said scale control means and wherein said scale control means controls said dispensing means to dispense a preselected weight with respect to a weight sensed by said scale means at the last action of said tar means so that said scale means may accommodate a plurality of sub-batches simultaneously. 
     
     
       24. A system according to claim 22, wherein each of said control means further includes display means connected to said scale control means for displaying information and said scale control means includes means for determining and providing to said display means sub-batch identification data. 
     
     
       25. A system according to claim 21, wherein said system interface means includes input means for inputting source of said batch and preselected quantity to form a sub-batch. 
     
     
       26. A system for monitoring the processing of a batch of raw material which separates desired material from its casing comprising: input means for inputting batch identification data, quantity data, and operator identification data;   measuring means for measuring a post-processing quantity of desired material; and   control means connected to said input means and said measuring means for receiving said data and measured post-processing quantity therefrom and determining yield from said input of batch quantity and measured post-processing quantity.   
     
     
       27. A system according to claim 26, wherein said control means includes first means for accumulating measurements of a first quality of desired material and second means for accumulating measurements of a second quality of desired material. 
     
     
       28. A system according to claim 26, wherein said input means inputs a target quantity of desired material for a job, and wherein said control means includes means for accumulating measurements and indicating when said target quantity has been reached. 
     
     
       29. A system according to claim 28, wherein said control means includes means for determining the period of time it took to meet said target quantity. 
     
     
       30. A system according to claim 26, wherein said control means includes means for correlating individual measurements with individual operator identifications. 
     
     
       31. A system according to claim 26, including means for distributing said raw material to a plurality of operators and means for transporting post-processed desired material with operator identification to said measuring means. 
     
     
       32. A system according to claim 31, wherein said control means includes means for correlating individual measurements with individual operator identifications. 
     
     
       33. A system according to claim 31, wherein said control means includes timing means for determining the period of time between the beginning of the distribution of said raw material and meeting a target quantity. 
     
     
       34. A system according to claim 33, wherein said timing means includes means for determining the period of time of a subsequent job which has began distribution of raw product before said target quantity has bene met for previous job. 
     
     
       35. A system for prompting an operator of a manual packaging operation comprising: weighing means for weighing a package and its contents; and   prompting means connected to said weighing means for determining and displaying to an operator, as a function of target weight and type of product to be packaged, full speed packaging, reduced speed packaging, and stop packing when a target weight has been reached.   
     
     
       36. A system according to claim 35, wherein said prompting means further displays adding one more product to reach target weight. 
     
     
       37. A system according to claim 36, wherein said prompting means further displays an over-target weight condition. 
     
     
       38. A system according to claim 35, including means for determining how many packages an operator has completed in a period of time. 
     
     
       39. A system according to claim 36, including means for determining said period of time. 
     
     
       40. A system according to claim 35, including a plurality of weighing means and associated prompting means and a control means connected to each of said prompting means for counting the number of packages completed by each operator and the total of all operators. 
     
     
       41. A system according to claim 40, wherein said control means includes means for indicating when said total for all operators meets a preselected value for given job. 
     
     
       42. A processing line data acquisition system for monitoring the processing of batches of raw material for a process line having sorting and first and second raw material processing steps comprising: first means for sorting batches of raw material by a preselected criteria into a plurality of grades and assigning a batch and grade related identification to the sorted raw material;   second means for determining said batch and grade related identification for all raw material inputted into a first process and assigning a first post-process identification;   third means for determining said first post-process identification for all first post-processed raw material inputted into a second process and assigning a second post-processing identification; and   central computer means connected to said first, second and third means for collecting said identifications and correlating them on a batch basis.   
     
     
       43. A system according to claim 42, wherein said first, second and third means each include means for measuring the quantity of material in each assigned identification and said central computer means includes means for determining yield on a batch as is using said measured quantities.